Installation Instructions for ILEA electric actuators ILEA-Ax ILEA-Bx ILEA-Px ILEA-Qx ILEA_IOM TABLE OF CONTENTS Designations... 2 Symbols and Safety... 2 Actuator Mounting... 3 General Safety... 4 Wiring & Commissioning... 4 Symbols and Safety... 5 Tracing Faults Charts... 6-7 ILEA_IOM_RevD_0716 92500136 No Rev
ACTUATOR PART DESIGNATIONS Pillar Coupling Coupling Nut Clamping Screws for Spring Pack Valve Stem Locking Nut Yoke Lock Nut Bracket Pillar Nut SYMBOLS AND SAFETY Please ensure that the detailed operating instructions and the chapter on Safety in particular have been read and understood by all personnel involved in the installation, start-up, operation, maintenance and repair of the actuators. Beware of mechanical hazards due to electrically powered actuator components! With the actuator powered electrically, operating the unit holds the danger of crushing your finger! Caution! During the installation of the actuator on the valve, the unit must not be powered electrically. Disconnect voltage from the actuator before maintenance and adjustment work. During adjustment work, the actuator must be operated by means of the handwheel only. Do not operate electrically! DO NOT FULLY EXTEND. 2 2600 Emrick Blvd Bethlehem, PA 18020 USA 800-922-0085 www.warrencontrols.com
BEFORE START WORKING: SAFETY REGULATIONS: Mounting - Disconnect mains! - Prevent reconnection! - Test for absence of harmful voltages! - Cover or close nearby live parts! ACTUATOR MOUNTING When mounting an actuator on a valve, always use the hand wheel! Motor operation during mounting may cause injuries and damage to actuator and valve! FOR MOUNTING THE ACTUATOR, THE VALVE MUST BE IN FULLY CLOSED POSITION! 1: Drive coupling upwards by hand 2: Position Jam nuts as per reference drawing and lock nuts together. *(H) Valve Height *(H) Number of Jam Nuts 18E 3.35 1 18M 3.91 1 28M 3.46 2 29E 3.46 2 29M 3.03 1 58E 3.46 2 58M 3.35 1 Pxx 2.67 2 3: Drop Actuator onto Valve assembly and tighten lock nut. 4: Extend Actuator by hand and lift valve stem to meet Actuator coupling. 5: Thread the valve stem into the coupling until the jam nuts meet the coupling. Lock the upper jam nut against the coupling. Lock the second jam nut against the upper nut. 6: Proceed ONLY AFTER following set-up and wiring on Pages 4 & 5. Use the commission function to complete the actuator mounting, detailed on the bottom of Page 5. GENERAL SAFETY ILEA actuators are built with state of the art technology and are safe to operate with commonly accepted electrical safety precautions. ILEA Actuators can also produce significant linear forces and should only be operated when connected to a control valve unless otherwise instructed. Fingers should not be anywhere near the moving parts of the valve and actuator assembly while power is connected. Operators should be trained, read the user manual and have a good understand of the actuator s function and operating capabilities. The wiring termination should be verified before commissioning commences. If the actuator was purchased together with a control valve the actuator will be precalibrated to the valve s stroke and there will be no other requirement than applying the correct power supply and control signal. The standard control signal is 4 20 ma where a 2-way valve is closed at 4mA and fully open at 20 ma. This standard configuration would be depicted on the product label for ILEA_IOM_RevD_0716 3
SET UP & GENERAL SAFETY Signal as 20-4 CL, to indicate it is a 4 20 ma signal and CLOSED at 4 ma. The actuator should be preprogrammed for control action and which signal is designated. Switching from a milliamp signal to a voltage signal is simply a matter of wiring termination. Switching whether the control signal is ZERO based or not, or the control action must be done in the software set up. This can be done on the job site as necessary with the programming umbilical cord option along with a laptop computer that has a USB connection. If this is required, contact the Warren Controls factory. CONTROL SIGNAL AND POSITION FEEDBACK CHOICES AND LABEL DESIGNATIONS. SIGNAL 2-WAY VALVE CLOSED LABEL DESIGNATION 3-WAY VALVE LOWER PORT CLOSED LABEL DESIGNATION 4 20 ma @ 4 ma 20 4 ma CL @ 4 ma 20 4 ma DN 4 20 ma @ 20 ma 4 20 ma CL @ 20 ma 4 20 ma DN 0 20 ma @ 0 ma 20 0 ma CL @ 0 ma 20 0 ma DN 0 20 ma @ 20 ma 0 20 ma CL @ 20 ma 0 20 ma DN 2 10 Vdc @ 2 Vdc 10 2 Vdc CL @ 2 Vdc 10 2 Vdc DN 2 10 Vdc @ 10 Vdc 2 10 Vdc CL @ 10 Vdc 2 10 Vdc DN 0 10 Vdc @ 0 Vdc 10 0 Vdc CL @ 0 Vdc 10 0 Vdc DN 0 10 Vdc @ 10 Vdc 0 10 Vdc CL @ 10 Vdc 0 10 Vdc DN With power applied, preferably, use a signal calibrator to verify that the valve is fully stroking from one end to the other as depicted by the travel indicator on the side of the actuator mounting Pillar and with the proper control action. Alternately the process controller could be directly connected to test if it has a Manual-Mode of operation where the controllers output can be manually adjusted from 0% - 100%. IF THE ACTUATOR IS ONE WITH A DEFINED FAIL-SAFE DIRECTION,THAT CAN BE VERIFIED BY: 1. Using the signal calibrator to move the actuator position to mid-stroke. 2. Safely disconnecting power at the power breaker switch and observing the actuator going to its fail-safe position. Once these steps are verified you may proceed to commissioning the control valve. If either of these tests did not perform as expected, then contact the Warren Controls factory for further troubleshooting steps. BASIC SAFETY NOTES: Before opening the actuator cover, ensure that the electrical mains supply voltage is disconnected. If operating the actuator with the cover removed for troubleshooting reasons make sure the wiring terminations are clearly understood. Contract the Warren Controls factory for further troubleshooting steps as may be necessary. Do NOT attempt to auto-stroke the actuator when the actuator is not connected to a control valve as it will not function. Do NOT adjust the Manual Override completely downward when the actuator is not connected to a control valve as this could permanently damage the actuator. If the actuator is removed from the control valve, upon reinstallation the auto-calibration procedure must be performed. Electric installation as well as over-current and over-voltage protection devices must be conform to the standard DIN IEC 60364-4-41, protection class I resp. protection class III (24VAC/24VDC) and also to the standard DIN IEC 60364-4-44 according to the applied over-voltage category of the actuator. Please protect all of the power supply and control cables in front of the terminals mechanically by using suitable measures against unintentional loosening. Never install the power supply and the control cables together in one conduit but instead please always use two different conduit. Remove connection terminal cover 4 2600 Emrick Blvd Bethlehem, PA 18020 USA 800-922-0085 www.warrencontrols.com
Electric supply for 1-phase AC/DC WIRING TERMINATION (A/B ONLY) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 TTL Button +0(2) - 10 V + 0(4) - 20 ma GND + 0(2) - 10 V + 0(4) - 20 ma GND max. Last/max. Load 100 ma/at 24 VD L/ + Open N/- 24 V AC/DC L/ + Close 115V- 230V AC N/- (24V AC/DC) L/+ (24V AC/DC) + 0(4) - 20 ma + 0(2) - 10 V 21-40 VDC/ 100 ma (OPTION) GND L/+(see tag plate) N/-(see tag plate) PE Control Signal Input Position Feedback Output Monitor relay potential-free Binary Input signals Fail safe signal Supply Actual value Closed Open Supply Voltage Fieldbus Interface PC Communication Commissioning Galvanically isolated 1 kv Process-Sensor Position switch potential-free contact COMMISSIONING ILEA actuators are commissioned at the factory when mounted to a control Valve. It must be commissioned if provided separately from a valve or has been dismounted. The actuator can only be commissioned when correctly mounted to a valve and with at least one cut off set to force/ torque. CAUTION! ELECTRICAL OPERATION OF THE ACTUATOR IS ALLOWED ONLY AFTER MOUNTING TO A VALVE! AUTOMATIC COMMISSIONING (Only available if at least one of the cut-offs is set to be by force/torque or by position automatically.) OPERATING DISPLAY CONTROLS 1 Press the commissioning button for 3 sec 2 Commissioning in progress (Green LED is flashing, actuator drives in both positions). 3 Green LED lights Actuator successfully commissioned and ready to be used. ILEA_IOM_RevD_0716 5
TRACING FAULTS CHARTS (A/B ONLY) Red LED Green LED Off Flashing slowly Flashing quickly Glowing permanently Off Flashing slowly Flashing quickly Glowing permanently Status Probable reasons Possible remedy x x Actuator does not respond, both LEDs are off x x Actuator does not drive the full stroke x x Actuator does not close the valve properly x x Actuator is in normal operating condition, but does not respond to set value changes x x Actuator position does not correspond to set value input 1) No supply voltage applied 2) The applied voltage does not match the actuator voltage on the tag plate 1) Actuator not correctly commissioned 2) Too small stroke programmed (in mode one position dependent cutoff ) 1) Actuator not correctly commissioned 2) Actuator closing force/ torque too low 1) Fixed digital set value is activated 2) Actuator is configured to work with process controller A non linear valve curve has been parameterised 1) Check mains supply 2) Apply correct supply voltage 1) Repeat commissioning 2) Check valve stroke parameters > see instructions AMS PSCS 1) Repeat commissioning 2) Check actuator selection 1) Check set value parameters > see instrucions AMS PSCS 2) Connect process sensor Verify parameterised characteristic > see instructions AMS PSCS Operating conditions Probable reasons Possible remedy x x Normal operating condition x x Actuator in commissioning mode Commissioning mode will be left automatically after completion x x Actuator not commissioned Depending on the type of cut offs, the actuator has to be commissioned either automatically or manually Faults within the actuator s environment Probable reasons Possible remedy x x Too high torque has been encountered within the valve stroke x x 1) No proper process feedback (only in combination with PSIC) 2+3) Maximum control range exceeds (only in combination with PSIC) 1) Actuator not correctly commissioned to the valve 2) Mechanical block within the stroke path 3) Improper selection of the actuator 1) Process feedback wrongly or not at all connected 2) Process feedback outside od adjusted range 3) No process sensor signal available 1) Repeat commissioning 2) Check valve and actuator for unobstructed running 3) Check actuator selection 1) Apply the correct process feedback signal and check polarity 2) Ensure the correct process feedback range 3) Check the process sensor and its supply voltage 6 2600 Emrick Blvd Bethlehem, PA 18020 USA 800-922-0085 www.warrencontrols.com
TRACING FAULTS CHARTS (A/B ONLY) Red LED Green LED Off Flashing slowly Flashing quickly Glowing permanently Off Flashing slowly Flashing quickly Glowing permanently Faults within the actuator s environment x x Actuator drives into a preset position x x Set value disconnected or outside the parameterized range Probable reasons 1) Signal is applied to the binary fail safe input 2) Supply voltage failure on actuators with optional PSCP 1) Set value not connected 2) Wrong polarity of setvalue 3) set value signal outside parameter range, please check Loose or dirty valve seat x x Stored end position could not be reached x x Stored end position has been passed over x x Actuator supply voltage too low 1) Improper wiring of the mains supply 2) Jitter in supply voltage 3) Too low supply voltage from PSEP (with optional PSEP) Possible remedy 1) Disconnect the signal 2) Check supply voltage 1) Apply set value 2) Check the set value polarity 3) Check the set value range Check the valve seat Valve seat worn or defective Check the valve seat 1) Check mains wiring 2) Check supply voltage > see datasheet 3) Contact PS service team Faults within the actuator Probable reasons Possible remedy x x Actuator has reached lifetime limit Wear and/ or running time Contact PS service team x x Faulty electronics or invalid parameters 1) Supply voltage interrupted during commissioning 2) Defective electronic component 1) Too high numbers of starts 2) Ambient temperature too high 1) Reload parameters ( > see manual AMS PSCS), then repeat commissioning 2) Contact PS service team x x Critical or maximum temperature reached 1) Check application and its adjustment 2) Check ambient temperature and try to reduce it > see relevant data sheet x x Mechanical fault in the actuator Defective mechanical part Contact PS service team ILEA_IOM_RevD_0716 7
ILEA_IOM_RevD_0716 92500136 No Rev 2600 EMRICK BLVD BETHLEHEM, PA 18020 USA 800-922-0085 WWW.WARRENCONTROLS.COM DEPENDABLE, RUGGED, PRECISION CONTROL VALVES AND ACCESSORIES